Mezo`s 1988 XT600Z 3AJ Rebuild Thread (Project Ténéré)

[Mezo]

Well i made a start on the bodywork, the plastics were in pretty bad shape & the fairing was cracked in several places.

I started rubbing down the panels just to see what i was going to be up against, i used an electric random orbital sander with 80 grit paper (i think).







I used fiberglass matting on the inside to hold the thing together & the excess that squeezed out i flatted with the sander again.







I used this magic stuff called "Spray Putty" on all the panels, it just seemed to float on similar to that floating floor compound.















Then it was just a case of wet & dry sanding them by hand until they was all nice & smooth.



Once i had done all that, sometimes having to add another layer of putty & sanding again i was ready for my primer.























Now i know your thinking what a nice prep job i did here, well i did do a nice job according to the painter except id used the wrong primer

He said,,,,it had all started cracking, i never saw this as he never told me until after he had painted it, he said he had to rub them down & put flexi primer on the panels, id don't know if this was bullshit or the truth? i had to take his word for it & just deal with it, but i was pretty gutted after all the hard Yakka id put in sanding/rubbing them down.

So word of caution to you budding resto guys reading this, on plastic use a flexi primer (according to my paint guy).

Mezo.

[Mezo]

Now the bodywork is off to the paintshop it allows me to start pulling stuff out of the "Box-O-Shite"

First up was the dash/fairing support which i blasted and then painted gloss black.





Then after it had dried i fitted it to the frame.









Then it was out with the crappy looking triples, first step before the forks & ultimately the front wheel.





Quick dusting with the sandblster.



And ready for painting.





Rattle rattle rattle, ptsssssss.







Then after drying a coat of clear it was time to fit them in the headstock with new races & bearings, to fit the upper races
i needed to improvise slightly & make a DIY press

I used an upside down hole saw & a big bolt right through to a nut & washer and just wound the bugger in there.













Dust cap fitted.



And then assembly.






Mezo.

[55W1985]

More Mark!!!!! Its adictive to see......

[Shano]

Forgot how ugly that thing was when you started Mez.

When do we get to the part where your fartsack gets deluged on the deck.

[Mezo]

I had some of the smaller graphics come through, one in particular i was waiting on was the yellow "MONO CROSS"

Getting this on would then allow me to clear coat it & get it finished off.







So i hung it up & out with the rattle can clear "Pftsssssss, chinka chinka chinka"









Then i set about cleaning up the rear brake caliper, very crusty yet thoroughly satisfying seeing them come back to life (eh Geoff).



Also decided to clean up the rear linkage as well.



After sandblasting.



Then a quick spray with rattle can silver "Ptssssss"









Then i could get the swing arm finished off & test fitted, i had a new shock boot rubber & new chain guides sent from the US.














Mezo.

[Mezo]

I then set about cleaning up the grubby forks, first off was a blast in the sandpit (hi tech stuff eh)





After a thorough sandblast it was time for the old rattle can "chinka, chinka, chinka"













Then on with the new rubber (which fell apart eventually) but looks good when i put them on.





Mezo.

[Mezo]

Finally a spare min to update my own thread.

Started painting the engine in VHT gloss black enamel (rattle can formula).



And the inspection covers in silver.







Same with the side covers.







Then came the donk (block, lump) your choice.







Then the head & barrel were next in line for the rattle can.







Then my buddy Tony Pie said "sand the fins" and thank jeebus he said that because it made all the difference.
First i just did the head & liked it so much i did the barrel & the rocker cover.

[youtube]imbjL4DADJA[/youtube]





So with it all painted i could start putting it all back together (with the help of my mate Wayne).









Then it was time to put the "donk" in the frame.













Mezo.

[Just Dan]

I had forgotten a lot of detail in your rebuild. Enjoying re reading it again.

[Mezo]

To be honest Dan i forgotten myself, i thought this would be a chore & its turned out to be a pleasure, thanks GB.

Wanker.

Mezo.

[Danjet600]

definitely enjoying back through all the threads again, over time i forgot all the little stuff